Truck axles are subjected to tremendous operational pressure on a daily basis. In order to ensure that it is strong enough to handle complex working conditions year after year, Volvo Trucks is using a brand new axle test rig. It is the largest of its kind in the world and can handle double rear axles weighing up to 32 tons. It can be said that it is unique now! Currently, the test stand is located at the Volvo plant in Gothenburg, Sweden. It only takes a few weeks for the staff to simulate the entire life cycle of a truck bridge that has been subjected to heavy work pressure. Previously, the same experiment required nearly 4 times the time to complete. As Göran Johansson, the head of Volvo’s pilot project said, “Now we use the new test stand to test, and in just 6 to 10 weeks, we can finish what we tested in the past 6 to 8 months. At the same time, The test bench also brought us better test results!" Maintaining product quality has always been the most important and time-consuming part of Volvo Trucks' product development and quality management. The new test bench reduced the original test time from several months to several weeks, greatly shortening the development time of Volvo truck products. In order to enable the design of a new generation of axles to cope with the overall structure of the vehicle and the operation of each part, and to make it more optimized, this test has become an important stage in the development process of Volvo trucks. Göran Johansson explained that "all the optimization process is to ensure that the truck's systems work properly, but also to ensure that the truck will not be overweight or waste of fuel due to the size of the axle. The world's largest truck axle test bench Volvo's new test bed is the largest of its kind in the world. It can handle double rear axles weighing up to 32 tons, which makes it the world's only axle test bed. The test bench has a weight of 220 tons and sits on a concrete block weighing close to 1,000 tons. During the test, the concrete block will contact different air cushions to relieve the huge impact force generated during the operation. At the same time, the air cushion will absorb the reaction force of the test stand and thus protect the safety of the factory where the test stand is located. Complex test simulation process In order to ensure the quality of the truck, it is necessary to carry out accurate tests on the various systems of the truck in a complex work cycle. The new test device can apply horizontal and vertical pressure to the entire axle of a Volvo truck at the same time or separately, as well as the torque of the wheels. During the test, researchers were able to obtain data from more than 100 test points. At the same time, in order to achieve the required accuracy of the simulation test, the parameters in the electronic controller connected to the test bench can be automatically updated more than 1000 times per second. Based on the data obtained from the tracking test of consumer-driven vehicles, the researchers set up different test procedures. For different testing sessions, the test rig can simulate the tremendous pressure on truck axles in a real-world working environment and run the appropriate basic procedures, including long-distance transportation, regional distribution, and construction site operations. In addition, the test link can be changed accordingly for special driving situations in different transportation links. appendix: Test bench related parameters • 14 meters long, 8 meters wide and 4.5 meters high • 220 tons dead weight, vibration base weight 980 tons • The hydraulic system contains 12 pumping pumps with an output of 2,000 kilowatts, capable of withdrawing 4900 liters of liquid per minute • Electronic controller update frequency is 1024 Hz.
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Volvo's new axle test rig simulates the life cycle of truck axles in weeks